Process of and apparatus for making concrete building elements



Nov. 24, 1925- S. LAKE PROCESS OF AND APPARATUS FOR MAKING CONCRETE BUILDING ELEMENTS O igin Filed Auei. 20, 1924 s Sheets- Sheet 1 Nov. 24, 1925- s. LAKE PROCESS OF AND APPARATUS FOR MAKING CONCRETE BUILDING ELEMENTS 3 Sheets-Sheet 2 Original Filed Aug. 20, 1924 my QN Nov. 24, 1925- 1,562,707

S. LAKE V PROCESS OF AND APPARATUS FOR MAKING CONCRETE BUILDING ELEMENTS riginal Filed Auet. 20, 1924 3 Sheets-Sheet 5 Patented Nov. 24, 1925.

SIMON LAKE, OF MILFORD. CONNECTICUT.

- PROCESS OF AND APPARATUS FOR MAKING Original application filed August 20, 1924, Serial No. 733,208.

To all whom it may concern:

Be it known that I, SIMON LAKE, a citizen of the United States, residing at Milford, in the county of New Haven and State of Connecticut, have invented a certain new and useful Improvement in Processes of and Apparatus for Making Concrete Building Elements, of which the following is a full, clear, and exact description.

This case is a division of my copending application for patent. for concrete building element, filed August 20, 1924, Serial No. 733,208.

This invention relates to a concrete building element suitable for use in the construction of walls, floors and roofs of buildings, and so designed and fabricated as to meet all of the requirements of strength, permanence and adaptability incident to its several uses.

One object of the invention is to provide a concrete building element which will lend itself readily to quantity production and shipment, and which may be used as a sub stitute for other building elements or materials.

Another object is to provide a building element of such a nature that it makes possible the construction of buildings in a much shorter time than has heretofore been possible, thus materially reducing the cost of construction. I

A further object is to provide a building element of such formation that a building constructed of same will be insulated against heat and cold, will be moisture and vermin proof, fire safe and sanitary.

The invention consists in a method ofand apparatus for making concrete building ele ments composed, in effect, of two slabs forming the faces of the element, and these slabs joined together and held in spaced relation to each other by longitudinal and transverse webs, the webs and the slabs provided with reinforcing and strengthening members tied together to form a reinforcing framework bonded in the concrete of the element, as-l will proceed now to explain and finally claim.

In the accompanying drawings illustrating the invention, in the several figures of which like parts are similarly designated, Figure l is a'fragmentary perspective view illustrating the various members of the reinforcing framework, Fig. 2 is a longitudinal CONCRETE BUILDING ELEMENTS.

Divided and this application filed January Serial No. 3,649.

section of a finished element. Fig. 3 is a fragmentary transverse section taken on the line 33 of Fig. 2. Fig. at is a fragmentary section similar to that of Fig. 2, but showing a modification. Figs. 5 and 6 are fragmentary sections illustrating the method and apparatus for forming the elements. Figs. 7 and 8 are top plan views of cores, such as shown in Fig. 6, for use in the manufacture of the elements. Fig. 9 is a section taken on the line 99 of Fig. 7. Fig. 10 is a perspective view of-a device, such as shown in Fig. 6, for supporting the cores during the operation of forming the elements. Figs. 11 and 12 are views similar to Fig. 6, but showing a modified form of cores and means for supporting same. Fig. 13 is a top plan view of a core of the type shown in Figs. 11 and 12. Fig. 1-1 is a section tarren on line 14-14 of Fig. 13.

My building elements may be made in a variety of shapes and sizes, and they may be provided with openings for doors and windows by the incorporation in them of suitable door and window frames. but for purposes of illustration I have shown an element of rectangular form, without openings.

The invention is best described by setting forth the method of its production, and this method may be stated as follows I take a plurality of transverse members or boards 1 provided on their inner faces with grooves 2 extending throughout their length and upon their outer faces with similar grooves 3. These members 1 are arranged in pairs and are suitably spaced apart by spacers 4 arranged adjacent to their ends, which spacers in addition to maintaining the members 1 in proper spaced relation serve as a means for connecting them by nails, screws or the like i, which are driven through the members 1 and into the spacers 4. The pairs of members 1 thus connected are then arranged at suitable spaced distances from each other and in number as required by the length of the building element to be formed and are maintained in such spaced relation by means of separator members 5 arranged between them and substantially midway of their length, as shown. As will be seen, particularly by reference to Fig. 1, the members 1 are slabbed off at their ends as at 6 and on these slabbed off portions are nailed or otherwise secured the edge pieces 7 provided with rablongitudinally of the framework. Afterthese bars 9 have been secured in place, wire mesh 10 is laid over the whole exposed surface of the framework with its longitudinal edges resting in the rabbets 8 of the edge pieces 7 and is nailed or stapled to these edge pieces and to the members 1. The

whole framework is then bodily turned over filled with concrete to approximately the and edge pieces 7 similar to the edge pieces 7 and provided with rabbets 8, are secured upon the slabbed ofi portions 6 of the members 1. Then longitudinal reinforcing rods 11 are stapled or otherwise suitably secured to the members 1. and wire mesh 12 is positioned over the whole exposed surface of the framework, with its longitudinal edges engaging with the rabbets 8 of the edge pieces 7', and is secured to the framework in the same manner as is the wire mesh 10. This structure comprises the foundation or main supporting and strengthening framework for the building element. 1

Referring now to Figs. 5 and 6, a layer of concrete or cement plaster 13 of suitable thickness and consistency is spread upon a pallet 14 preferably of hollow construction providing aspace 15 into which steam or other heating fluid may be introduced, for a purpose later explained, and then the whole framework .just described, with the side carrying the bars 9 downward, is placed upon this layer of concrete 13 and is worked into same until the wire mesh 10 and members 9 are embedded therein. Then a hoelike levelling tool 16, provided on its edges with pins 17 and with a handle 18, is run into the spaces between the pairs of members 1, with its-pins 17 finding bearings and guides in the grooves 3 of the members 1 and the concrete in these spaces is screeded oif to a uniform thickness and surface conformation. As will be seen, the members 1 are provided with undercut grooves 19 on their upper and lower edges which, due to.

their dove-tail shape, form a retaining connection or bond with the concrete, thus anchoring the concrete to them in addition to its bond with the bars 9 and wire mesh 10.

After the molding operation has been car-' ried this far, transverse reinforcing rods 20' are inserted inthe spaces 21, the spaces are level of the grooves 2, and insulating members or strips 22 are then slid into the grooves 2 from the ends of the members 1. These insulating members are provided with appropriately positioned openings 23 and 24. and through these openings and into the plastic concrete are forced reinforcing rods 25 and 26, respectively, and through similar openings 27 are lnserted reinforcing and tying members 28 which bond with the concretebelow the insulating members 22 and are hooked over the longitudinal rods 11. After these various elements have been positioned as described, the filling of the spaces between the members 1 above the insulating members 22 with concrete may be completed if desired, and the transverse reinforcing rods 20 may be inserted, or these latter'operations may be deferred until the top portionor slab of the element is formed.

The above operations having been completed, and the concrete 13 forming the lower slab of the element having acquired sufficient set to sustain an appreciable load, but

being still plastic and capable of uniting with additional concrete, the top portion orslab of the element may be formed as follows:

Boards or the like 29 having hinged to them cam members 30 provided with handles 31, as shown in detail in Fig. 10, are laid upon the lower slab of the element, as shown in Fig. 6, but with the cam members 30 turned down so as to lie fiat upon the boards 29. Then the cores illustrated in Figs. 6, 7,

8 and 9 are slid into the spaces between ad* jacent pairs of members 1, and the handles 31 are .turnedto raise the, cam members 30 to thereby elevate the cores to casting position, as shown in Fig. 6'. With the cores in this position, concrete is spread over the whole upper surface of the frame of the element, and is worked through the wire mesh 12, sufiicient concrete being supplied to form a substantial coating above the mesh 12, as shown in Fig. 2, and is screeded off to the desired uniform thickness, the cores. arranged as described forming a bed to receive the concrete thus applied.

It is during this operation that the filling of the spaces 21 betweenthe members 1 may be completed and the rods 20' inserted, as hereinbefore indicated, and I prefer to follow this procedure. I

This last operation completes the casting or molding of the element.

In order to quickly dry out the concrete to hasten its acquiring sucli a set as will permit the handling of the element without danger of fracture, I prefer to artificially heat the entire concrete body. and this I do bv th introduction of steam into the space 15' of the pallet 14 and into the interior of the cores.

By reference to Figs. 7 and 9, it will be seen that the cores are of waffie-like formation as regards their surface contour and comprise using the hinged cam to drop below the edges 42 engaging with of strips 46,- as shown nally of the under face of the upper slab of the element and containing the rod 11, and broken only bv the members 1 ofthe re inforcing framework. 1

Fig. 8 shows a modified'form of core in which in addition to the depression 34 there is a transverse depression 35 which with the depression 34divides the surface of the core into four raised portions 36and provides in addition to the longitudinal rib 34 an in- 'termediate transverse rib upon the under side of the upper slab of the element.

After the eoncretehas attainedits initial set, the cores may be withdrawn by turning the handles 31 to move the cam members 30 to their lowered position thus lowermg the cores so that they may be disengaged from the ribs formed by them and may be there after withdrawn.

Steam for heating the cores may be in troduced into them through pipes 37 having connected with them a plurality of nozzles 39, one in each of the divisions of the cores. In Figs. 11 to 14 inclusive, I have shown a modified form of core and means for utilizing the same In this modified form, the

core isconstructed preferably entirely of sheet metal and comprises a base 39 upon which are mounted the inverted pan-shaped members 40 having lips or flanges 41 around which the edges of the base member are crimped as at 42, the joints being welded or soldered, as desiredpto make them steamtight. f

A metal duct 43 corresponding to the steam pipe 37 is suitably attached as by welding or otherwise to the base member 39 and with this duct 40 the lower edges of'these grooves, and may then raise them to casting position bymeans 1n Fig. 11. After the castingprocess is completed, the strips 46 may be removed andthecores allowed to drop down to the-position shown in-Fig.

- 12, in which they are capable OfKbeing withq drawn without interference.

that when they engage with the lower the pins 17 of the hoe Obviouslytwhere enlarged grooves 3 of this type are provided in the members 1, member 16 will be so positioned at the sides of the hoe member f edges 0 be used, wherein the extend beyond the edges.

are connected the nozzles 44 for admitting steam to the chan1 may be nailed,

shown in Fi 3 t W and resting .upontributed.

the groovesthe bottom or working edge of the hoe member will be properly positioned and supported relatively to the concrete layer to be screeded. I I

Houses'constructedwf my building elements may be of such size that a single element will suffice for each wall thereof and for the floors and roofs, or it maybe necessary to use a number of the elements to construct a wall, floor or roof.

When a single element only is needed for a wall, floor or roof, the edges of the element may be finished as shown in Fig. 4 by casting concrete upon its ends and edges, such concrete bonding with the reinforcing elements which extend beyond the edges of the, reinforcing framework, lVhere a plurality of elements must be used, elements such as shown in Fig. 2 may reinforcing elements In uniting adjacent elements of this last -mentioned type,

the abutting ends of the bars '9 and rods 11 are welded or otherwise united, and the wire mesh of adjacent elements is laced or otherwise'oined or merel overla ed and then the space between the elements and including these, interlocked and welded reinforcing elements is filled with a strong grout which is screeded off into uniformity with the surfaces of the adjacent elements, to form in effect a continuous unbroken face;

The above refers principally to the join ing of the endsof the building elements, but

it will be apparent that it may be necessary in structures of considerable size, or containing a number of stories, element edge wise upon another. When my elements are to be'used in this relationship, it. may be found expedient to leave their edges unfinished, so that an air space will extend from the center of one element to the (enter ofthe next adjacent element, but if this is not desired, the ends of the cored openings, and the spaces 21 between the members 1 may be closed by boards or insulating material 47 .upon which wire mesh 48 and concrete applied thereto to complete the edges of the member as Bymy construction, 'itwill'be seen that I provide'a concrete building element having a reinforcing framework adapted to absorb longitudinal and transverse strains, and having reinforcing elements combined with the reinforcing framework and bonded with the concrete for distributing pressures exerted upon the building element from above and below whether localized or evenly dis- Moreover, I produce a building element comprising in effect two slabs of concrete spaced apart to form dead air spaces capable of insulating a structure composed of said elements against heat, cold and moisture, and with strengthening webs of cow to superpose one L crete connecting these two slabs at intervals by cooperation with the reinforcing frame-- work of the elements, but insulated from each other by means of the insulating members 22, between the members 1, and similar insulating members 22', Fig. 3, between the separator members 5. I o

I produce, by my invention, a building element of very light weight relative to its size, of great strength, and of low cost per foot as compared with materials now in use.

As an indication of the strength of elements of my design, it has been found practicable to construct such elements 12 ft. 6 in. wide by 28 ft. 5 in. long by 3% in. thick, with a 2 in. air space, thus making the upper and lower slabs only in. thick. Such a slab when only thirteen days old'was found on official test to be capable of supporting a load of eighty pounds per square foot without damage of any sort.

Referring to Fig. 4, it will be seen that, if desired, the value of the dead air space as an insulator against transmission through the element of heat, cold, moisture and sound may be enhanced 'by the addition of an insulating partition member 50 which may be slid into the grooves 3 and positioned thereby in spaced relation to the upper and lower slabs of the elementfthus forming two dead air spaces insulated from each other by the member 50. l a -As' hereinbefore indicated, when the element is .used in substantially horizontal position for the construction of floors or roofs, its reinforcing members are capable of sustaining loads tributed, and whether applied from above or below, and when used in vertical position, as in a wall, will sustain loads applied from 1 either side.

, contemplated as wit ing elements Moreover, it will be seen that, due to the arrangement of f the members comprising the reinforcing framework proper, and of the reinforcing rods, bars, wire mesh and other elements applied thereto and embedded in the concrete of the slabs andwebs, loads, no matter how or where applied u on the element, will bedistributed and a sorbed throughout the whole element.

Various changes in the method of and'apparatus'for carrying out my invention are in the spirit of the invention and the scope of the" following claims.

What I claim. is

1. A. method of fabricating concrete buildcomprising a a- 'reinforcin framework, an upper slab and alower sla of concrete and interconnecting spacing webs' uniting said slabs, which consists in spreadin a layer of concrete of required area and thickness to form the bottom slab, embedding said framework therein, screeding off surplus concrete within said framework,

either localized orevenly disarea and'thickness to form thebottom slab,-

embedding said framework therein, screeding off surplus concrete within said framework, supporting cores above the thus screeded concrete slab, depositing concrete upon said cores, screeding off the thus deposited concrete to thethickness desired to thus form the top slab of the element, a plying heat to' the concrete .to hasten tiie initial set thereof, and thereafter removing said cores. 3. A method of fabricating concrete building elements comprising" areinforcin framework, an upper slab and a lower sla of concrete and interconnecting spacing webs uniting said slabs, which cons1stsin spreading a layer of concrete of required area and thickness to form the bottom slab,

embedding said frameworktherein, screed-.

ing off surplus concrete within said framework, supporting cores above the thus screeded concrete slab, depositing concrete upon said cores, screeding off the thus de posited concrete to. the thickness desired to thus form the top slab of the element, introducing a heating medium into said cores to dry said concrete to hasten the initial set thereof, and thereafter removing said cores.

' 4. A method of fabricating concretebuilding elements comprising a reinforcing framework, an upper-slab and a lower slab of concrete and interconnecting spacing webs uniting said slabs, which consists in spreading upon a pallet a layer of concrete of required area and thickness to form the bot-' tom slab, embedding said framework therein, s'creeding off surplus concrete within said framework, supporting cores above the thus screeded concrete slab,depositing concrete upon said cores, screedin off the thus deposited concrete to the thickness desired to 7 thus form the top slab of the element, introducing a heating medium into said cores and pallet to dry said concrete to hasten the initial set-thereof, and thereafter removing said cores.

5. In apparatus for making a concrete.

buildihg element, a reinforcing framework comprising a plurality of pairs of transverse members provided with grooves in their outer faces, means for connectlng and pos to be supported within said tioning said pairs of members in predetermined relationship, said framework adapted to be embedded in concrete, and said grooves adapted to support and guide a member whereby the concrete may be screeded to a uniform contour and thickness between adjacent pairs of members during the operation of casting the element. Y

6-. In apparatus for making a concrete building element, a reinforcing framework comprising a plurality of pairs of transverse members provided with grooves in their outer faces, means for connecting and positioning said pairs of members in predetermined relationship, said framework adapted to be embedded in concrete, and said grooves adapted to support and guide a hoe member whereby the concrete may be screeded to a uniform contour and thickness between adj acent pairs of members during the operation of casting the element.

7. Apparatus for fabricating concrete building elements of the type described having a reinforcing framework and spaced interconnected slabs, comprisin a'casting pallet upon which concrete may be deposited to form one of said slabs, a hoe member adapted to be supported and guided by said framework for screedin'g off said concrete to the desired thickness, and cores adapted to be supported within said framework above said concrete to receive concrete for forming the other of said slabs,

8. Apparatus for fabricating concrete building elements of the type described having a reinforcing framework and spaced interconnected slabs, comprising a casting pallet upon which concrete may be deposited to form one of said slabs, a hoe member adapt.-

ed to be supported and guided by said framework for screeding off said concrete to the desired thickness, hollow cores adapted framework above said concrete to receive concrete for forming the other of said slabs, and means for introducing a heating medium into said cores for hastening the setting of the concrete.

9. Apparatus for fabricating concrete building elements of the type described havceive concrete for ing a reinforcing framework and spaced interconnected slabs, comprising a hollow casting pallet upon which concrete may be deposited to form one of said slab-s, a hoe member adapted to be supported and guided by said framework for screeding off said concrete to the desired thickness, and hollow cores adapted to be supported within said frmaework above said concrete to receive concrete for forming the other of said slabs, said pallet and cores adapted to be heated for the purposeof drying the concrete to hasten its setting. I

10. In apparatus for making a concrete building element having an upper and a lower slab, a reinforcing framework comprising a plurality of pairs of transverse members provided with grooves in their outer faces, means for connecting and positioning said pairs of members in predetermined relationship, a pallet adapted to reformin the lower slab and in which concrete said framework is embedded, and cores adapted to be" positioned by said grooves and supported therein t-p lfeceive concre e for forming said upper s a 11.-In apparatus for making a concrete building element having an upper and a lower slab, a reinforcing framework comprising a plurality of pairs of transverse members provided with grooves in their outer faces, means for connecting and positioning said pairs of members in predetermined relationship, a pallet adapted to receive concrete for forming said lower slab and in which concrete said framework is .embedded, cores adapted to be positioned by said grooves, and strips arranged for cooperation with said grooves and cores and adapted when inserted in said grooves to raise said cores to position for receiving concrete to form said top slab and when re moved therefrom to allow said cores to drop to position in which they may be removed.

In testimony whereof I have hereunto set my hand this 19th day of January, A. D.

SIMON LAKE. k 

